Construction system and method and related articles

ABSTRACT

A drawer assembly includes a bottom, a first side extending from the bottom, and a second side extending from the bottom and opposite the first side. The second side includes a first wall portion and a second wall portion opposite the first wall portion. The first wall portion is spaced apart from the second wall to define a first cavity therebetween. The first wall portion includes a first aperture in fluid communication with the first cavity.

CROSS REFERENCE TO RELATED APPLICATIONS

This U.S. patent application is a continuation-in-part of, and claimspriority under 35 U.S.C. § 120 from, U.S. patent application Ser. No.14/233,669, filed on Dec. 27, 2018, which is a divisional of U.S. patentapplication Ser. No. 15/657,390, filed on Jul. 24, 2017, now U.S. Pat.No. 10,201,226, issued on Feb. 12, 2019, which is a continuation-in-partof U.S. patent application Ser. No. 15/407,921, filed on Jan. 17, 2017,now U.S. Pat. No. 10,034,543, issued on Jul. 31, 2018. The disclosuresof these prior applications are considered part of the disclosure ofthis application and are hereby incorporated by reference in theirentireties.

FIELD

The present disclosure relates to a system and method for constructingan article, and more particularly to articles having a folded construct.

BACKGROUND

This section provides background information related to the presentdisclosure and is not necessarily prior art.

Laminated substrates are often used to manufacture various types offurniture and fixtures for homes and offices. For example, countertops,drawer boxes, speaker boxes, and other items are often manufactured fromwood, or a wood composite, having a polymer laminate.

While known furniture and known furniture manufacturing methods haveproven useful for their intended purposes, a need for continuousimprovement in the pertinent art remains.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

One aspect of the disclosure provides a drawer assembly. The drawerassembly may include a bottom, a first side extending from the bottom,and a second side extending from the bottom opposite the first side. Thesecond side may include a first wall portion and a second wall portionopposite the first wall portion. The first wall portion may be spacedapart from the second wall portion to define a first cavitytherebetween. The first wall portion may include a first aperture influid communication with the first cavity.

This aspect may include one or more of the following optional features.In some implementations, the drawer assembly includes a third sideextending between the first side and the second side.

In some implementations, a front component is detachably connected tothe third side.

In some implementations, the first wall portion includes a secondaperture spaced apart and linearly aligned with the first aperture. Thesecond aperture may be in communication with the first cavity.

In some implementations, a first component is detachably connected tothe second side.

In some implementations, portions of the first component are disposedthrough the first and the second apertures.

In some implementations, the first component is a drawer track.

In some implementations, the front component includes a first portionhaving a first and a second end, and a second portion spaced apart andopposing the first portion.

In some implementations, the second portion of the front componentextends from the first end of the first portion in a direction towardsthe second end of the first portion. The second portion may terminatebefore the second end of the first portion.

In some implementations, the front component includes a second cavitydisposed between the first portion and the second portion. A portion ofthe third side of the drawer assembly may be disposed within the secondcavity.

In some implementations, the second portion of the front componentincludes a first and a second cutout. A portion of the first side of thedrawer assembly may be disposed within the first cutout. A portion ofthe second side of the drawer assembly may be disposed within the secondcutout.

In some implementations, the front component includes a third and afourth aperture. The third side of the drawer assembly may include afifth and a sixth aperture. The third aperture may be aligned with thefifth aperture. The fourth aperture may be aligned with the sixthaperture.

In some implementations, a handle is detachably coupled to the frontcomponent. A portion of the handle may be disposed within the third,fourth, fifth, and sixth apertures.

Another aspect of the disclosure provides a method of assembling adrawer assembly. The method includes folding a substrate at a firstchannel to form a first side. The method also includes folding thesubstrate at a second channel to form a second side. The method furtherincludes folding the substrate at a third channel, a fourth channel, anda fifth channel to form a third side having a first cavity. The methodalso includes folding the substrate at a sixth channel, a seventhchannel, and an eighth channel to form a fourth side having a secondcavity.

This aspect may include one or more of the following optional features.In some implementations, the method further includes applying anadhesive to at least one of the first channel, the second channel, thethird channel, the fourth channel, the fifth channel, the sixth channel,the seventh channel, and the eighth channel prior to folding.

In some implementations, the third side of the substrate includes afirst aperture in communication with the first cavity. The fourth sideof the substrate may include a second aperture in communication with thesecond cavity.

In some implementations, the method further includes detachablyconnecting a first component to an outer surface of the third side ofthe substrate, and detachably connecting a second component to an outersurface of the fourth side of the substrate.

In some implementations, a portion of the first component is disposedthrough the first aperture of the third side of the substrate. A portionof the second component may be disposed through the second aperture ofthe fourth side of the substrate.

In some implementations, the first and the second components are drawertracks.

In some implementations, the method further includes detachablyconnecting a front component to the first side of the substrate. Thefront component may be configured to cover the first side of thesubstrate.

In some implementations, the front component includes a third cavity.The first side of the substrate may be disposed within the third cavity.

In some implementations, the front component includes a first and asecond cutout. The third side of the substrate may be disposed withinthe first cutout and the fourth side of the substrate may be disposedwithin the second cutout.

In some implementations, the front component includes a first aperture.The first side of the substrate may include a second aperture. The firstaperture may be aligned with the second aperture.

In some implementations, the method further includes detachablyconnecting a handle to the front component of the drawer assembly. Aportion of the handle may be disposed within the first aperture of thefront component and the second aperture of the first side of thesubstrate.

The details of one or more implementations of the disclosure are setforth in the accompanying drawings and the description below. Otheraspects, features, and advantages will be apparent from the descriptionand drawings, and from the claims.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected configurations and are not intended to limit the scope of thepresent disclosure.

FIG. 1 is a perspective view of a furniture unit in accordance with theprinciples of the present disclosure;

FIG. 2 is an exploded view of the furniture unit of FIG. 1;

FIG. 3 is a top view of the furniture unit of FIG. 1;

FIG. 4A is an end view of a shelf for use with the furniture unit ofFIG. 1;

FIG. 4B is an exploded view of the shelf of FIG. 4A;

FIG. 5 is an end view of a shelf for use with the furniture unit of FIG.1;

FIG. 6 is an end view of a shelf for use with the furniture unit of FIG.1;

FIG. 7A is a top view of a substrate prior to forming a shelf for usewith the furniture unit of FIG. 1;

FIG. 7B is an end view of a shelf formed with the substrate of FIG. 7Aand for use with the furniture unit of FIG. 1;

FIG. 7C is a top view of a substrate prior to forming a ceiling baffle;

FIG. 7D is a perspective view of a ceiling baffle formed with thesubstrate of FIG. 7C;

FIG. 8 is an end view of a shelf for use with the furniture unit of FIG.1;

FIG. 9 is an end view of a shelf for use with the furniture unit of FIG.1;

FIG. 10 is an end view of a bedrail in accordance with the principles ofthe present disclosure;

FIG. 11 is an end view of another bedrail in accordance with theprinciples of the present disclosure;

FIG. 12 is an end view of another bedrail in accordance with theprinciples of the present disclosure;

FIG. 13A is a perspective view of a bedrail assembly in a partiallyassembled state in accordance with the principles of the presentdisclosure;

FIG. 13B is a perspective view of the bedrail assembly of FIG. 13A in anassembled state in accordance with the principles of the presentdisclosure;

FIG. 14A is cross-sectional view of a substrate during a method ofmanufacturing the furniture unit of FIG. 1;

FIG. 14B is cross-sectional view of a substrate during a method ofmanufacturing the furniture unit of FIG. 1;

FIG. 14C is cross-sectional view of a substrate during a method ofmanufacturing the furniture unit of FIG. 1;

FIG. 14D is cross-sectional view of a substrate during a method ofmanufacturing the furniture unit of FIG. 1;

FIG. 15 is a perspective view of a drawer assembly in accordance withthe principles of the present disclosure;

FIG. 16A is a top view of a substrate prior to forming a box componentof the drawer assembly of FIG. 15;

FIG. 16B is a bottom view of the substrate of FIG. 16A prior to formingthe box component of the drawer assembly of FIG. 15;

FIG. 16C is a perspective view of the box component of the drawerassembly of FIG. 15 during a method of manufacturing;

FIG. 17A is a perspective view of a front component of the drawerassembly of FIG. 15;

FIG. 17B is a top view of a substrate prior to forming the frontcomponent of FIG. 17A;

FIG. 18A is a cross-sectional view of the drawer assembly of FIG. 15taken along line 18A-18A of FIG. 15.

FIG. 18B is a cross-sectional view of the drawer assembly of FIG. 15taken along line 18B-18B of FIG. 15.

FIG. 18C is a cross-sectional view of the drawer assembly of FIG. 15taken along line 18C-18C of FIG. 15; and

FIG. 19 is a side view of the drawer assembly of FIG. 15.

Corresponding reference numerals indicate corresponding parts throughoutthe drawings.

DETAILED DESCRIPTION

Example configurations will now be described more fully with referenceto the accompanying drawings. Example configurations are provided sothat this disclosure will be thorough, and will fully convey the scopeof the disclosure to those of ordinary skill in the art. Specificdetails are set forth such as examples of specific components, devices,and methods, to provide a thorough understanding of configurations ofthe present disclosure. It will be apparent to those of ordinary skillin the art that specific details need not be employed, that exampleconfigurations may be embodied in many different forms, and that thespecific details and the example configurations should not be construedto limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particularexemplary configurations only and is not intended to be limiting. Asused herein, the singular articles “a,” “an,” and “the” may be intendedto include the plural forms as well, unless the context clearlyindicates otherwise. The terms “comprises,” “comprising,” “including,”and “having,” are inclusive and therefore specify the presence offeatures, steps, operations, elements, and/or components, but do notpreclude the presence or addition of one or more other features, steps,operations, elements, components, and/or groups thereof. The methodsteps, processes, and operations described herein are not to beconstrued as necessarily requiring their performance in the particularorder discussed or illustrated, unless specifically identified as anorder of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” “attached to,” or “coupled to” another element or layer,it may be directly on, engaged, connected, attached, or coupled to theother element or layer, or intervening elements or layers may bepresent. In contrast, when an element is referred to as being “directlyon,” “directly engaged to,” “directly connected to,” “directly attachedto,” or “directly coupled to” another element or layer, there may be nointervening elements or layers present. Other words used to describe therelationship between elements should be interpreted in a like fashion(e.g., “between” versus “directly between,” “adjacent” versus “directlyadjacent,” etc.). As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describevarious elements, components, regions, layers and/or sections. Theseelements, components, regions, layers and/or sections should not belimited by these terms. These terms may be only used to distinguish oneelement, component, region, layer or section from another region, layeror section. Terms such as “first,” “second,” and other numerical termsdo not imply a sequence or order unless clearly indicated by thecontext. Thus, a first element, component, region, layer or sectiondiscussed below could be termed a second element, component, region,layer or section without departing from the teachings of the exampleconfigurations.

With reference to FIGS. 1-3, a furniture unit 10 is provided. While thefurniture unit 10 is generally shown and described herein as being abookcase, it will be appreciated that the furniture unit 10 (e.g.,shelves, legs, backer, etc.), or parts thereof, may include, orotherwise be utilized as, other types of home or office furniture orfixtures (e.g., tables, bed frames, desks, doors, ceiling panels,ceiling baffles, etc.) within the scope of the present disclosure.

The furniture unit 10 may include one or more shelf sections 12-1, 12-2,. . . 12-n, one or more connectors 14-1, 14-2, . . . 14-n, and one ormore caps 16-1, 16-2, . . . 16-n. Each shelf section 12-1, 12-2, . . .12-n may include a shelf 18, a lateral leg 20, a medial leg 22, and abacker 24. The shelf 18 may extend from a lateral end 26 to a medial end28 opposite the lateral end 26. The lateral leg 20 may be coupled to, orotherwise supported by, the lateral end 26 of the shelf 18. The medialleg 22 may be coupled to, or otherwise supported by, the medial end 28of the shelf 18. As illustrated in FIG. 3, the backer 24 may be coupledto, or otherwise supported by, the shelf 18, the lateral leg 20, and/orthe medial leg 22.

As illustrated in FIG. 2, the lateral and medial legs 20, 22 may eachdefine a substantially hollow construct having upper and lower openings30, 32. The upper and lower openings 30, 32 may define any of a varietyof shapes. For example, while the upper and lower openings 30, 32 aregenerally illustrated as defining rectangular (e.g., square) shapes, itwill be appreciated that the upper and lower openings may define anothershape such as a triangle, a circle, or another polygon within the scopeof the present disclosure. In some implementations, the lateral and/ormedial leg 20, 22 may include the shelf 18, or a construct substantiallysimilar thereto. For example, the lateral leg 20 may define anothershelf, substantially similar or identical to shelf 18, supported by thelateral end 26 of the shelf 18, and the medial leg 22 may define anothershelf, substantially similar or identical to shelf 18, supported by themedial end 28 of the shelf 18.

With further reference to FIG. 2, the connectors 14-1, 14-2, . . . 14-nmay each include a first coupling portion 34, a second coupling portion36, and a stop portion 38. The first and second coupling portions 34, 36may define any of a variety of shapes. For example, while the first andsecond coupling portions 34, 36 are generally illustrated as definingrectangular (e.g., square) shapes, it will be appreciated that the firstand second coupling portions 34, 36 may each define another shape suchas a triangle, a circle, or another polygon within the scope of thepresent disclosure. In this regard, the size and shape of the first andsecond coupling portions 34, 36 may correspond to the size and shape ofone or both of the upper or lower openings 30, 32 of the lateral andmedial legs 20, 22, such that the upper or lower openings 30, 32 canreceive the first or second coupling portions 34, 36 of the connectors14-1, 14-2, . . . 14-n in an assembled configuration, as described inmore detail below.

The stop portion 38 may extend outwardly from, or otherwise relative to,the first or second coupling portions 34, 36 of the connectors 14-1,14-2, . . . 14-n. In some implementations, the stop portion 38 definesan outwardly extending flange relative to the first and second couplingportions 34, 36. In this regard, the stop portion 38 may define a shapethat is substantially similar to the shape defined by the first orsecond coupling portions 34, 36.

The caps 16-1, 16-2, . . . 16-n may each include a coupling portion 40and a stop portion 42. The coupling portion 40 may define any of avariety of shapes. For example, while the coupling portion 40 isgenerally illustrated as defining a rectangular (e.g., square) shape, itwill be appreciated that the coupling portion 40 may define anothershape such as a triangle, a circle, or another polygon within the scopeof the present disclosure. In this regard, the size and shape of thecoupling portion 40 may correspond to the size and shape of one or bothof the upper or lower openings 30, 32 of the lateral and medial legs 20,22, such that the upper or lower openings 30, 32 can receive thecoupling portion 40 of the caps 16-1, 16-2, . . . 16-n in an assembledconfiguration, as described in more detail below. The stop portion 42may extend outwardly from, or otherwise relative to, the couplingportion 40 of the caps 16-1, 16-2, . . . 16-n. In some implementations,the stop portion 42 defines an outwardly extending flange at, andrelative to, an uppermost portion of the coupling portion 40. In thisregard, the stop portion 42 may define a shape that is substantiallysimilar to the shape defined by the coupling portion 42.

As illustrated in FIGS. 1 and 2, in the assembled configuration, theshelf sections 12-1, 12-2, . . . 12-n may be arranged in a stackedconfiguration. In this regard, the lateral leg 20 of the first shelfsection 12-1 may be removably coupled to the lateral leg 20 of thesecond shelf section 12-2, and the medial leg 22 of the first shelfsection 12-1 may be removably coupled to the medial leg 22 of the secondshelf section 12-2. For example, one or more connectors 14-1, 14-2, . .. 14-n may be removably coupled to the lateral leg 20 of the first shelfsection 12-1 and to the lateral leg 20 of the second shelf section 12-1,and another one or more connectors 14-1, 14-2, . . . 14-n may beremovably coupled to the medial leg 22 of the first shelf section 12-1and to the medial leg 22 of the second shelf section 12-1. Inparticular, the first coupling portion 34 of one or more of theconnectors 14-1, 14-2, . . . 14-n may be disposed within one or more ofthe upper openings 30 of the lateral leg 20 of the first shelf section12-1, and the second coupling portion 36 may be disposed within one ormore of the lower openings 32 of the lateral leg 20 of the second shelfsection 12-2, such that the stop portion 38 engages the lateral legs 20of the first and second shelf sections 12-1, 12-2. Similarly, the firstcoupling portion 34 of one or more of the connectors 14-1, 14-2, . . .14-n may be disposed within one or more of the upper openings 30 of themedial leg 22 of the first shelf section 12-1, and the second couplingportion 36 may be disposed within one or more of the lower openings 32of the medial leg 22 of the second shelf section 12-2, such that thestop portion 38 engages the medial legs 22 of the first and second shelfsections 12-1, 12-2.

With reference to FIGS. 4A and 4B, the shelf 18 may include, orotherwise be formed from, a substrate 46 having a layered construct. Inthis regard, the substrate 46 may include a base layer 48, an upperlaminate layer 50, and a lower laminate layer 52. The base layer 48 andthe upper and lower laminate layers 50, 52 may each be formed from oneor more of a variety of materials. In some implementations, the baselayer 48 is formed from a medium-density fiberboard material, a polymermaterial (e.g., polyvinyl chloride), or a particle board material, andthe laminate layers 50, 52 are formed from a paper material or a polymermaterial (e.g., polypropylene).

The base layer 48 may include an upper surface 54, a lower surface 56opposite the upper surface 54, and a peripheral surface 58. The upperand lower surfaces 54, 56 may extend from a proximal portion 60 of thesubstrate 46 to a distal portion 62 of the substrate 46. The peripheralsurface 58 may extend from the upper surface 54 to the lower surface 56.In this regard, the peripheral surface 58 may include a proximalperipheral surface 64, a distal peripheral surface 66, a lateralperipheral surface 68, and a medial peripheral surface 70. The proximalperipheral surface 64 may be disposed in the proximal portion 60 of thesubstrate 46. The distal peripheral surface 66 may be disposed in thedistal portion 62 of the substrate 46 opposite the proximal peripheralsurface 64. The lateral peripheral surface 68 may extend from theproximal peripheral surface 64 to the distal peripheral surface 66. Themedial peripheral surface 70 may extend from the proximal peripheralsurface 64 to the distal peripheral surface 66 opposite the lateralperipheral surface 68.

The upper laminate layer 50 may include an upper surface 74, a lowersurface 76 opposite the upper surface 74, and a peripheral surface 78.The upper and lower surfaces 74, 76 may extend from the proximal portion60 of the substrate 46 to the distal portion 62 of the substrate 46. Theperipheral surface 78 may extend from the upper surface 74 to the lowersurface 76. In this regard, the peripheral surface 78 may include aproximal peripheral surface 80, a distal peripheral surface 82, alateral peripheral surface 84, and a medial peripheral surface 86. Theproximal peripheral surface 80 may be disposed in the proximal portion60 of the substrate 46. The distal peripheral surface 82 may be disposedin the distal portion 62 of the substrate 46 opposite the proximalperipheral surface 80. The lateral peripheral surface 84 may extend fromthe proximal peripheral surface 80 to the distal peripheral surface 82.The medial peripheral surface 86 may extend from the proximal peripheralsurface 80 to the distal peripheral surface 82 opposite the lateralperipheral surface 84.

The lower laminate layer 52 may include an upper surface 88, a lowersurface 90 opposite the upper surface 88, and a peripheral surface 92.The upper and lower surfaces 88, 90 may extend from the proximal portion60 of the substrate 46 to the distal portion 62 of the substrate 46. Theperipheral surface 92 may extend from the upper surface 88 to the lowersurface 90. In this regard, the peripheral surface 92 may include aproximal peripheral surface 94, a distal peripheral surface 96, alateral peripheral surface 98, and a medial peripheral surface 100. Theproximal peripheral surface 94 may be disposed in the proximal portion60 of the substrate 46. The distal peripheral surface 96 may be disposedin the distal portion 62 of the substrate 46 opposite the proximalperipheral surface 94. The lateral peripheral surface 98 may extend fromthe proximal peripheral surface 94 to the distal peripheral surface 96.The medial peripheral surface 100 may extend from the proximalperipheral surface 94 to the distal peripheral surface 96 opposite thelateral peripheral surface 98.

In the assembled configuration, the upper surface 54 of the base layer48 may engage the lower surface 76 of the upper laminate layer 50, andthe lower surface 56 of the base layer 48 may engage the upper surface88 of the lower laminate layer 52, such that the upper surface 74 of theupper laminate layer 50, the lower surface 90 of the lower laminatelayer 52, the peripheral surface 58 of base layer 48, the peripheralsurface 78 upper laminate layer 50, and the peripheral surface 92 oflower laminate layer 52 define outermost surfaces of the substrate 46.In some implementations, the upper surface 54 of the base layer 48 maybe bonded to the lower surface 76 of the upper laminate layer 50 usingan adhesive or other suitable technique, and the lower surface 56 of thebase layer 48 may be bonded to the upper surface 88 of the lowerlaminate layer 52 using an adhesive or other suitable technique. Whilethe substrate 46 is generally shown and described herein as includingthe base layer 48, the upper laminate layer 50, and the lower laminatelayer 52, the substrate 46 may include the base layer 48 and one of theupper and lower laminate layers 50, 52 within the scope of the presentdisclosure. In this regard, in some implementations, the upper surface54 or the lower surface 56 of the base layer 48 may define an outermostsurface of the substrate 46.

As illustrated in FIG. 4A, the shelf 18 may include, or otherwisedefine, a first seam 104-1, a second seam 104-2 spaced apart from thefirst seam 104-1, and a third seam 104-3 spaced apart from the first andsecond seams 104-1, 104-2. It will be appreciated that the shelf 18 mayinclude more or less than three seams within the scope of the presentdisclosure. For example, as illustrated in FIG. 4A, in someimplementations, the shelf 18 may include first, second and third seams104-1, 104-2, 104-3 in the proximal portion 60 of the substrate 46, andfourth, fifth, and sixth seams 104-4, 104-5, 104-6 in the distal portion62 of the substrate 46. The seams 104-1, 104-2, 104-3 may extend throughthe base layer 48. Where the substrate 46 includes the base layer 48 andboth of the upper and lower laminate layers 50, 52, the seams 104-1,104-2, 104-3 may extend through the base layer 48 and through one of theupper and lower laminate layers 50, 52. Where the substrate 46 includesthe base layer 48 and one of the upper and lower laminate layers 50, 52,the seams 104-1, 104-2, 104-3 may extend through only the base layer 48.The seams 104-1, 104-2, . . . 104-n may extend from the lateralperipheral surfaces 68, 84, 98 to the medial peripheral surfaces 70, 86,100. In this regard, the seams 104-1, 104-2, 104-3 may extend in adirection substantially parallel (+/−5 degrees) to the proximalperipheral surfaces 64, 80, 94 or the distal peripheral surfaces 66, 82,96.

With continued reference to FIGS. 4A and 4B, the shelf 18 may furtherinclude, or otherwise define, a first fold 106-1, a second fold 106-2spaced apart from the first fold 106-1, and a third fold 106-3 spacedapart from the first and second folds 106-1, 106-2. It will beappreciated that the shelf 18 may include more or less than three foldswithin the scope of the present disclosure. In this regard, the number“n” of folds 106-1, 106-2, . . . 106-n may equal the number of seams104-1, 104-2, . . . 104-n. Where the substrate 46 includes the baselayer 48 and both of the upper and lower laminate layers 50, 52, thefolds 106-1, 106-2, 106-3 may be formed in the one of the upper andlower laminate layers 50, 52 which does not include the seams 104-1,104-2, 104-3. Where the substrate 46 includes the base layer 48 and oneof the upper and lower laminate layers 50, 52, the folds 106-1, 106-2,106-3 may be formed in that one of the upper and lower laminate layers50, 52. The folds 106-1, 106-2, 106-3 may extend from the lateralperipheral surfaces 68, 84, 98 to the medial peripheral surfaces 70, 86,100. In some implementations, the folds 106-1, 106-2, 106-3 extend in adirection substantially parallel (+1-5 degrees) to the proximalperipheral surfaces 64, 80, 94 or the distal peripheral surfaces 66, 82,96. In this regard, each fold 106-1, 106-2, . . . 106-n may be alignedwith one of the seams 104-1, 104-2, . . . 104-n.

With reference to FIGS. 4 and 14A-14D, a method of manufacturing anycomponent of shelf section 12-1, 12-2, . . . 12-n (i.e, shelf 18,lateral leg 20, medial leg 22, and backer 24) of the furniture unit 10will now be described. The component of shelf section 12-1, 12-2, . . .12-n may be manufactured from the substrate 46 having a thickness Textending between an upper surface (e.g., upper surface 74) and a lowersurface (e.g., lower surface 90). The thickness T may be between twomillimeters and ten millimeters. In some implementations, the thicknessT may be substantially equal to five millimeters.

With particular reference to FIG. 14A, the method may include providinga tool 200 (e.g., a router, a blade, a bit, etc.) and using the tool toform a plurality of primary channels 202 in the substrate 46, e.g., bymiter cutting the plurality of primary channels 202 in the substrate 46.In this regard, the number and location of the primary channels 202 maycorrespond to the number and location of the seams 104-1, 104-2, . . .104-n or the number and location of the folds 106-1, 106-2, . . . 106-n.The tool 200 may include a male portion 203 and a female portion 205opposite the male portion 203. As illustrated, in some configurations,the male portion 203 defines a convex profile and the female portion 205defines a concave profile. It will be appreciated, however, that themale and female portions 203, 205 may define other profiles (e.g.,triangular, rectangular, etc.) within the scope of the presentdisclosure. In this regard, the size and shape of the male portion 203may correspond to, or otherwise be the same as, the size and shape ofthe female portion 205. Accordingly, as illustrated in FIG. 14A, theprimary channels 202 may be defined by a first channel wall 204 having amale portion 207 formed by the female portion 205 of the tool 200, and asecond channel wall 206 having a female portion 209 formed by the maleportion 203 of the tool 200.

The first and second channel walls 204, 206 may extend through amajority of the thickness T of the substrate 46. For example, the firstand second channel walls 204, 206 may extend through betweenapproximately seventy percent of the thickness T of the substrate 46 andninety-nine percent of the thickness T of the substrate 46. In someimplementations, the first and second channel walls 204, 206 may extendthrough an entirety of the base layer 48 and through an entirety of thelower laminate layer 52. In this regard, the first and second channelswalls 204, 206 may define a common edge 208 adjacent the lower surface76 of upper laminate layer 50, and have an angle α therebetween. Theangle α may be between about fifteen degrees and about one hundredsixty-five degrees. As illustrated in FIG. 14A, in some implementations,the angle α is substantially equal to ninety degrees.

With continued reference to FIG. 14A, the method may further includeproviding a tool 210 and forming one or more secondary channels 212 inthe substrate 46. As illustrated in FIG. 14A, the secondary channels 212may extend through the lower laminate layer 52 to expose the lowersurface 56 of the base layer 48. In this regard, forming the secondarychannels 212 may include removing a portion of the lower laminate layer52. The secondary channels 212 may extend from the lateral peripheralsurfaces 68, 84, 98 to the medial peripheral surfaces 70, 86, 100.

With reference to FIG. 14B, the method may also include folding thesubstrate 46 such that each first channel wall 204 of primary channel202 engages the second channel wall 206 of the same of primary channel202 to define a corresponding seam 104-n and fold 106-n. In this regard,the female portion 209 of each primary channel 202 may receive the maleportion 207 of such primary channel 202. For example, the method mayinclude performing a plurality of folding operations to define theplurality of seams 104-1, 104-2, . . . 104-n and the plurality of folds106-1, 106-2, . . . 106-n. In this regard, each fold 106-1, 106-2, . . .106-n may define, or otherwise act as, a hinge for folding the substrate46. Accordingly each fold 106-1, 106-2, . . . 106-n may be referred toherein as a hinge 106-1, 106-2, . . . 106-n. As illustrated in FIGS. 4Aand 4B, in some implementations, the folding operations, and theplurality of seams 104-1, 104-2, . . . 104-n and the plurality of folds106-1, 106-2, . . . 106-n defined thereby, forms a hollow proximalsupport 214 at the proximal portion 60 of the substrate 46 and a hollowdistal support 216 at the distal portion 62 of the substrate 46. Thehollow proximal support 214 and/or the hollow distal support 216 maydefine a polygonal cross section extending from the lateral peripheralsurfaces 68, 84, 98 to the medial peripheral surfaces 70, 86, 100. Forexample, the hollow proximal support 214 and the hollow distal support216 may define a rectangular (e.g., square) cross section extending fromthe lateral peripheral surfaces 68, 84, 98 to the medial peripheralsurfaces 70, 86, 100. In this regard, the upper surface 74 of the upperlaminate layer 50 may include a first portion 218 and a second portion219. The first portion 218 may extend from the proximal peripheralsurface 80 to a first seam 104-1, and the second portion 219 may extendfrom the first seam 104-1 to a second seam 104-2. The first portion 218and the second portion 219 may define an angle θ therebetween. The angleθ may be between about fifteen degrees and about one hundred sixty-fivedegrees. As illustrated in FIGS. 4 and 14B, in some implementations, theangle θ is substantially equal to ninety degrees.

With reference to FIG. 14C, folding the substrate 46 may also includeengaging the proximal peripheral surfaces 64, 80, or 94 or the distalperipheral surfaces 66, 82, or 96 with the upper surface 54 of the baselayer 48 or with the lower surface 56 of the base layer 48. Inparticular, folding the substrate 46 may include positioning theproximal peripheral surfaces 64, 80, 94 or the distal peripheralsurfaces 66, 82, 96 within one of the secondary channels 212 such thatthe proximal peripheral surfaces 64, 80, 94 or the distal peripheralsurfaces 66, 82, 96 engage the upper surface 54 or the lower surface 56of the base layer 48. In this regard, the proximal peripheral surfaces64, 80, 94 or the distal peripheral surfaces 66, 82, 96 may define anangle β relative to one or more of the upper surfaces 54, 74, 88 or thelower surfaces 56, 76, 90. For example, the proximal peripheral surfaces64, 80, 94 or the distal peripheral surfaces 66, 82, 96 may define anangle β relative to the lower surface 90. The angle β may be betweenabout ninety degrees and about one hundred eighty degrees. For example,if the hollow support portion 214 defines a rectangle the angle θ may besubstantially equal to ninety degrees. If the hollow support portion 214defines a triangle the angle β may be greater than ninety degrees. Insome implementations, if the hollow support portion 214 defines atriangle, the angle (3 may be substantially equal to one hundred twentydegrees.

In some implementations, engaging the proximal peripheral surfaces 64,80, or 94 or the distal peripheral surfaces 66, 82, or 96 with the uppersurface 54 of the base layer 48 or with the lower surface 56 of the baselayer 48 may also include coupling the proximal peripheral surfaces 64,80, or 94 or the distal peripheral surfaces 66, 82, or 96 with the uppersurface 54 of the base layer 48 or with the lower surface 56 of the baselayer 48 using an adhesive or other suitable technique.

As illustrated in FIGS. 4A and 4B, in some implementations, folding thesubstrate 46 to form the hollow proximal support 214 and/or the hollowdistal support 216 includes folding the proximal portion 60 in acounterclockwise direction and folding the distal portion 62 in aclockwise direction.

With continued reference to FIG. 14C, the method may also includeforming one or more apertures 220 through the substrate 46 and placing aprimary connector 222 in each of the one or more apertures 220. Forexample, the method may include forming the one or more apertures 220through the hollow proximal support 214 or the hollow distal support216. The primary connector 222 may include a cross-dowel having anaperture 224 formed therein.

With reference to FIG. 14D, the method may further include coupling theshelf 18 to the lateral leg 20 or the medial leg 22. In someimplementations, the method may include coupling a secondary connector226 to each of the primary connectors 222 to couple the shelf 18 to thelateral leg 20 and the medial leg 22. For example, the method mayinclude extending the secondary connectors 226 through the lateral leg20 or the medial leg 22 and into the aperture 224 of the primaryconnector 222. In some implementations, extending the secondaryconnector 226 into the aperture 224 of the primary connector 222includes threadably engaging the secondary connector 226 with theprimary connector 222 within the aperture 224.

With reference to FIG. 5, another shelf 18 a for use with the furnitureunit 10 is shown. The structure, function, and method of manufacturingthe shelf 18 a may be substantially similar to that of the shelf 18,apart from any exceptions described below and/or shown in the Figures.Accordingly, the structure and/or function of similar features will notbe described again in detail. In addition, like reference numerals areused hereinafter and in the drawings to identify like features, whilelike reference numerals containing letter extensions (i.e., “a”) areused to identify those features that have been modified.

The shelf 18 a may include the hollow proximal support 214 and a hollowdistal support 216 a. As illustrated in FIG. 5, the hollow proximalsupport 214 and the hollow distal support 216 a may be disposed onopposite sides of the shelf 18 a. In this regard, folding the substrate46 to form the hollow proximal support 214 may include folding theproximal portion 60 in a counterclockwise direction, and folding thesubstrate 46 to form the hollow distal support 216 a may include foldingthe distal portion 62 in a counterclockwise direction.

With reference to FIG. 6, another shelf 18 b for use with the furnitureunit 10 is shown. The structure, function, and method of manufacturingthe shelf 18 b may be substantially similar to that of the shelf 18,apart from any exceptions described below and/or shown in the Figures.Accordingly, the structure and/or function of similar features will notbe described again in detail. In addition, like reference numerals areused hereinafter and in the drawings to identify like features, whilelike reference numerals containing letter extensions (i.e., “b”) areused to identify those features that have been modified.

The shelf 18 b may include a hollow support 216 b extending from theproximal portion 60 to the distal portion 62 of the substrate 46. Inthis regard, folding the substrate 46 to form the hollow support 216 bmay include folding the proximal portion 60 in a counterclockwisedirection, or folding the distal portion 62 in a clockwise direction,such that the proximal peripheral surfaces 64, 80, or 94 are disposedadjacent the distal peripheral surfaces 66, 82, or 96.

With reference to FIGS. 7A and 7B, another shelf 18 c (FIG. 7A) formedfrom the substrate 46, and for use with the assembly 10, is shown. Thestructure, function, and method of manufacturing the shelf 18 c may besubstantially similar to that of the shelf 18 b, apart from anyexceptions described below and/or shown in the Figures. Accordingly, thestructure and/or function of similar features will not be describedagain in detail. In addition, like reference numerals are usedhereinafter and in the drawings to identify like features, while likereference numerals containing letter extensions (i.e., “c”) are used toidentify those features that have been modified.

The substrate 46 of the shelf 18 c may include the hollow support 216 bextending from the proximal portion 60 to the distal portion 62 of thesubstrate 46, and one or more covers 227. The cover 227 may engage aportion 228 of the lateral peripheral surfaces 68, 84, or 98 or aportion 228 of the medial peripheral surfaces 70, 86, or 100. Asillustrated in FIG. 7B, in some implementations, the shelf 18 c may havetwo covers 227; one cover 227 may engage a portion 228 of the lateralperipheral surfaces 68, 84, or 98 and the other cover 227 may engage aportion 228 of the medial peripheral surfaces 70, 86, or 100. In thisregard, in these implementations, the shelf 18 c may have the appearanceof a solid piece (e.g., a solid piece of wood) without any openings. Thesubstrate 46 may further include a fold 230 that may be formed in one ofthe upper and lower laminate layers 50, 52 such that one of the uppersurfaces 54, 74, 88 or one of the lower surfaces 56, 76, 90 engages theportion 228 of the lateral peripheral surfaces 68, 84, or 98 or themedial peripheral surfaces 70, 86, or 100. In some implementations, theshelf 18 c may be utilized as a ceiling panel or baffle.

In other implementations, the shelf 18 c may be formed without one orboth of the covers 227, or without one or more of the seams 104-1,104-2, . . . 104-n, such that the shelf 18 c defines a four-sidedconstruct or a five-sided construct in which each side defines a ninetydegree angle relative to any adjacent sides. For example, with referenceto FIGS. 7C and 7D, a five-sided ceiling baffle 18 c′ (FIG. 7D), formedfrom the substrate 46, is shown. The structure, function, and method ofmanufacturing the ceiling baffle 18 c′ may be substantially similar tothat of the shelf 18 c, apart from any exceptions described below and/orshown in the Figures. In this regard, the substrate 46 may define aceiling baffle 18 c′ having an opening 229 into the hollow support 216c′.

With reference to FIG. 8, another shelf 18 d for use with the furnitureunit 10 is shown. The structure, function, and method of manufacturingthe shelf 18 d may be substantially similar to that of the shelf 18,apart from any exceptions described below and/or shown in the Figures.Accordingly, the structure and/or function of similar features will notbe described again in detail. In addition, like reference numerals areused hereinafter and in the drawings to identify like features, whilelike reference numerals containing letter extensions (i.e., “d”) areused to identify those features that have been modified.

The shelf 18 d may include a support 216 d defining a corrugatedconstruct extending from the proximal portion 60 to the distal portion62 of the substrate 46. In this regard, folding the substrate 46 to formthe support 216 d may include folding one or more portions of thesubstrate in a clockwise direction and a counterclockwise direction,such that one of the upper surfaces 54, 74, 88 or one of the lowersurfaces 56, 76, 90 engages another one of the upper surfaces 54, 74, 88or one of the lower surfaces 56, 76, 90. As illustrated in FIG. 8,folding the substrate 46 may include directly engaging various portionsof the lower surface 56 of the base layer 48 with various other portionsof the lower surface 56 of the base layer 48. In other implementations,folding the substrate 46 may include directly engaging various portionsof the upper surface 54 of the base layer 48 with various other portionsof the upper surface 54 of the base layer 48

With reference to FIG. 9, another shelf 18 e for use with the furnitureunit 10 is shown. The structure, function, and method of manufacturingthe shelf 18 e may be substantially similar to that of the shelves 18and 18 b, apart from any exceptions described below and/or shown in theFigures. Accordingly, the structure and/or function of similar featureswill not be described again in detail. In addition, like referencenumerals are used hereinafter and in the drawings to identify likefeatures, while like reference numerals containing letter extensions(i.e., “e”) are used to identify those features that have been modified.While article 18 e is generally shown and described herein as being a“shelf 18 e,” it will be appreciated that article 18 e may be utilizedin various ways within the scope of the present disclosure. For example,shelf 18 e may be utilized as a “shelf” for a bed. In this regard, theshelf 18 e may be utilized, and referred to herein, as a bedrail.

The shelf 18 e is a variation of the shelves 18 and 18 b shown in FIGS.4 and 6, including a hollow proximal support 214 e and the hollow distalsupport 216 b, and excluding lower laminate layer 52. In particular, theshelf 18 e may include the hollow support 216 b extending from theproximal portion 60 to the distal portion 62 of the substrate 46.Folding the substrate 46 may include forming the hollow proximal support214 e by folding the proximal portion 60 in a counterclockwisedirection, and forming the hollow distal support 216 b by folding thesubstrate 46 in a clockwise direction from the proximal portion 60 tothe distal portion 62 such that the proximal peripheral surfaces 64, 80are disposed adjacent the distal peripheral surfaces 66, 82. In someimplementations, the proximal peripheral surfaces 64, 80 and the distalperipheral surfaces 66, 82 engage the lower surface 56 of the base layer48. In this regard, the upper surface 74 of the upper laminate layer 50may include a first portion 232 (e.g., a forward portion) extending froma first seam 104-1 to the proximal peripheral surfaces 64, 80, and asecond portion 234 (e.g., a rearward portion) extending from a secondseam 104-2 to the distal peripheral surfaces 66, 82. The first portion232 of the upper surface 74 may engage the second portion 234 of theupper surface 74. In some implementations, the first portion 232 of theupper surface 74 is attached to the second portion 234 of the uppersurface 74. For example, the the first portion 232 of the upper surface74 may be coupled to the second portion 234 of the upper surface 74 withan adhesive or other suitable fastening technique. The substrate 46 ofshelf 18 e also may include lower laminate layer 52 such that theproximal peripheral surfaces 64, 80, or 94 are disposed adjacent thedistal peripheral surfaces 66, 82, or 96; and in some implementations,the proximal peripheral surfaces 64, 80, or 94 and the distal peripheralsurfaces 66, 82, or 96 engage the lower surface 90 of the lower laminatelayer 52. In some implementations, the proximal peripheral surfaces 64,80, or 94 and the distal peripheral surfaces 66, 82, or 96 are attachedto the lower surface 90 of the lower laminate layer 52.

With reference to FIG. 10, a bedrail 18 f is shown. The structure,function, and method of manufacturing the bedrail 18 f may besubstantially similar to that of the shelves 18, 18 b, 18 e, etc. apartfrom any exceptions described below and/or shown in the Figures.Accordingly, the structure and/or function of similar features will notbe described again in detail. In addition, like reference numerals areused hereinafter and in the drawings to identify like features, whilelike reference numerals containing letter extensions (i.e., “f”) areused to identify those features that have been modified. While article18 f is generally shown and described herein as being a “bedrail 18 f,”it will be appreciated that article 18 f may be utilized in various wayswithin the scope of the present disclosure. For example, the bedrail 18f may be utilized as a “shelf” for use with the furniture unit 10.

The bedrail 18 f is a variation of the shelf 18 e shown in FIG. 9,including a hollow proximal support 214 f and a hollow distal support216 f. In some implementations, the bedrail 18 f, like the shelf 18 e,excludes the lower laminate layer 52. In other implementations, thebedrail 18 f, like the shelf 18, includes the lower laminate layer 52.In particular, the bedrail 18 f may include the hollow support 216 fextending from the proximal portion 60 to the distal portion 62 of thesubstrate 46.

Folding the substrate 46 may include forming the hollow proximal support214 f by folding the proximal portion 60 in a counterclockwisedirection, and forming the hollow distal support 216 f by folding thesubstrate 46 in a clockwise direction from the proximal portion 60 tothe distal portion 62 such that the proximal peripheral surfaces 64, 80face a first direction and the distal peripheral surfaces 66, 82 face asecond direction opposite (e.g., approximately 180 degrees offset) thefirst direction. The first portion 232 may extend from the first seam104-1 to a third seam 104-3 f and from the third seam 104-3 f to theproximal peripheral surfaces 64, 80, and the second portion 234 mayextend from the second seam 104-2 to a fourth seam 104-4 f and from thefourth seam 104-4 f to the distal peripheral surfaces 66, 82. Inparticular, the first portion 232 may extend in the first direction fromthe third seam 104-3 f to the proximal peripheral surfaces 64, 80, andthe second portion 234 may extend in the opposite second direction fromthe fourth seam 104-4 f to the distal peripheral surfaces 66, 82.

A portion of the upper surface 74 of the upper laminate layer 50, aswell as the proximal peripheral surfaces 64, 80 and the distalperipheral surfaces 66, 82, may engage the lower surface 56 of the baselayer 48, while the first portion 232 of the upper surface 74 may engagethe second portion 234 of the upper surface 74. In some implementations,the first portion 232 of the upper surface 74 is attached to the secondportion 234 of the upper surface 74. For example, the first portion 232of the upper surface 74 may be coupled to the second portion 234 of theupper surface 74 with an adhesive or other suitable fastening technique.

As previously described, the substrate 46 of the bedrail 18 f also mayinclude lower laminate layer 52 (not shown) such that the proximalperipheral surfaces 64, 80, or 94 face in a direction opposite thedistal peripheral surfaces 66, 82, or 96; and in some implementations,the proximal peripheral surfaces 64, 80, or 94 and the distal peripheralsurfaces 66, 82, or 96 engage the lower surface 90 of the lower laminatelayer 52.

With reference to FIG. 11, a bedrail 18 g is shown. The structure,function, and method of manufacturing the bedrail 18 g may besubstantially similar to that of the bedrail 18 f apart from anyexceptions described below and/or shown in the Figures. Accordingly, thestructure and/or function of similar features will not be describedagain in detail. In addition, like reference numerals are usedhereinafter and in the drawings to identify like features, while likereference numerals containing letter extensions (i.e., “g”) are used toidentify those features that have been modified. While article 18 g isgenerally shown and described herein as being a “bedrail 18 g,” it willbe appreciated that article 18 g may be utilized in various ways withinthe scope of the present disclosure. For example, the bedrail 18 g maybe utilized as a “shelf” for use with the furniture unit 10.

The bedrail 18 g is a variation of the bedrail 18 f shown in FIG. 10,including the hollow distal support 216 f. In some implementations, thebedrail 18 g, like the bedrail 18 f, excludes the lower laminate layer52. In other implementations, the bedrail 18 g, like the bedrail 18 f,includes the lower laminate layer 52. In particular, the bedrail 18 gmay include the hollow support 216 f extending from the proximal portion60 to the distal portion 62 of the substrate 46. Folding the substrate46 may include forming the hollow distal support 216 f by folding thesubstrate 46 in a clockwise direction from the proximal portion 60 tothe distal portion 62 such that the proximal peripheral surfaces 64, 80face a first direction and the distal peripheral surfaces 66, 82 face asecond direction opposite (e.g., approximately 180 degrees offset) thefirst direction. In this regard, the distal peripheral surfaces 66, 82and a portion of the upper surface 74 of the upper laminate layer 50 mayengage the lower surface 56 of the base layer 48, while the secondportion 234 of the upper surface 74 may be exposed. In someimplementations, the upper surface 74 of the upper laminate layer 50 isattached to the lower surface 56 of the base layer 48. For example, theupper surface 74 of the upper laminate layer 50 may be coupled to thelower surface 56 of the base layer 48 with an adhesive or other suitablefastening technique. In some implementations, the proximal peripheralsurfaces 64, 80 are aligned (e.g., flush or coplanar) with the secondportion 234 of the upper surface 74.

As previously described, the substrate 46 of the bedrail 18 g also mayinclude lower laminate layer 52 (not shown) such that the proximalperipheral surfaces 64, 80, or 94 face in a direction opposite thedistal peripheral surfaces 66, 82, or 96; and in some implementations,the distal peripheral surfaces 66, 82, or 96 engage the lower surface 90of the lower laminate layer 52.

With reference to FIG. 12, a bedrail 18 h is shown. The structure,function, and method of manufacturing the bedrail 18 h may besubstantially similar to that of the bedrail 18 f apart from anyexceptions described below and/or shown in the Figures. Accordingly, thestructure and/or function of similar features will not be describedagain in detail. In addition, like reference numerals are usedhereinafter and in the drawings to identify like features, while likereference numerals containing letter extensions (i.e., “h”) are used toidentify those features that have been modified. While article 18 h isgenerally shown and described herein as being a “bedrail 18 h” it willbe appreciated that article 18 h may be utilized in various ways withinthe scope of the present disclosure. For example, the bedrail 18 h maybe utilized as a “shelf” for use with the furniture unit 10.

The bedrail 18 h is a variation of the bedrail 18 f shown in FIG. 10,including the hollow proximal support 214 f and a hollow distal support216 h. In some implementations, the bedrail 18 h, like the bedrail 18 f,excludes the lower laminate layer 52. In other implementations, thebedrail 18 h, like the bedrail 18 f, includes the lower laminate layer52. In particular, the bedrail 18 f may include the hollow support 216 hextending from the proximal portion 60 to the distal portion 62 of thesubstrate 46. Folding the substrate 46 may include forming the hollowdistal support 216 h by folding the substrate 46 in a clockwisedirection from the proximal portion 60 to the distal portion 62 suchthat the proximal peripheral surfaces 64, 80 face in a directionopposite (e.g., approximately 180 degrees offset) the distal peripheralsurfaces 66, 82. The first portion 232 may extend from the first seam104-1 to the proximal peripheral surfaces 64, 80, and the second portion234 may extend from the second seam 104-2 to the distal peripheralsurfaces 66, 82. A portion of the upper surface 74 of the upper laminatelayer 50, as well as the proximal peripheral surfaces 64, 80 and thedistal peripheral surfaces 66, 82, may engage the lower surface 56 ofthe base layer 48, while the first portion 232 of the upper surface 74may engage the second portion 234 of the upper surface 74.

In some implementations, the bedrail 18 h includes a plurality of seams104-3 h, 104-4 h, . . . 104-nh disposed between the second seam 104-2and the proximal portion 60 of the substrate 46. As illustrated in FIG.12, in some implementations, the bedrail 18 h may include three seams104-nh. It will be appreciated, however, that the bedrail 18 h mayinclude more or less than three seams 104-nh within the scope of thepresent disclosure. In forming the hollow distal support 216 h byfolding the substrate 46 in a clockwise direction, as previouslydescribed, from the proximal portion 60 to the distal portion 62, aportion of the upper surface 74 of the upper laminate layer 50, and aportion of the lower surface 56 of the substrate 46, may define amulti-sided shape. In this regard, a portion of the upper surface 74 anda portion of the lower surface 56 may each define a portion of apolygon. For example, a portion of the upper surface 74 and a portion ofthe lower surface 56 may each define a plurality (e.g., three) of sidesof a polygon. For example, as illustrated in FIG. 12, a portion of theupper surface 74 and a portion of the lower surface 56 may define aplurality of sides of a hexagon, an octagon, a decagon, or other similarpolygon extending between the second seam 104-2 and another of the seams104-3 n. In this regard, if the portion of the upper surface 74 and theportion of the lower surface 56 define a plurality of sides of anoctagon, the angle defined by adjacent seams of the plurality of seams104-3 h, 104-4 h, . . . 104-nh may be substantially equal to ninetydegrees. The portion of the upper surface 74 may be substantiallyparallel to the portion of the lower surface 56. In this regard,depending on the number of seams 104-3 n, the portion of the uppersurface 74 and the portion of the lower surface 56 may define, orotherwise resemble, a segmented arcuate shape (e.g., semi-cylindrical).

With reference to FIGS. 13A and 13B, a bedrail assembly 300 is shown.While article 300 is generally shown and described herein as being a“bedrail assembly 300,” it will be appreciated that article 300 may beutilized in various ways within the scope of the present disclosure. Forexample, the bedrail assembly 300 may be utilized as a “shelf” for usewith the furniture unit 10.

The bedrail assembly 300 may include a splice member 302 and one or moreof the shelves 18, 18 a, 18 b, 18 c, 18 d, 18 e or one or more of thebedrails 18 f, 18 g, 18 h. In this regard, while the bedrail assembly300 is generally shown and described as including two of the bedrails 18f, it will be appreciated that the bedrails 18 f of the bedrail assembly300 may be replaced with one or more of the shelves 18, 18 a, 18 b, 18c, 18 d, 18 e or one or more of the bedrails 18 f, 18 g, 18 h within thescope of the present disclosure. Accordingly, while article 300 isgenerally shown and described herein as being a “bedrail assembly 300”it will be appreciated that article 300 may be utilized in various wayswithin the scope of the present disclosure. For example, the bedrailassembly 300 may be utilized as a “shelf assembly” for use with thefurniture unit 10.

The splice member 302 may be formed from wood, metal, polymer, or othersuitable structural material and may define a cross-sectional shape thatis substantially the same as a void defined by the shelves 18, 18 a, 18b, 18 c, 18 d, 18 e or the bedrails 18 f, 18 g, 18 h. For example, thecross-sectional shape of the splice member 302 may be substantially thesame as the shape of the void defined by the hollow distal support 216 fof the bedrail 18 f. In this regard, the void may be defined by thelower surface 56 of the base layer 48. The cross-sectional size of thevoid defined by the surface 56 of the base layer 48 may be smaller orlarger than the cross-sectional size of the splice member 302.

Assembling the bedrail assembly 300 may include placing the splicemember 302 within the hollow distal support 216 f of two bedrails 18 f(e.g., FIG. 13A) and moving a first of the bedrails 18 f toward thesecond of the bedrails 18 f. For example, assembling the bedrailassembly 300 may include moving a first of the bedrails 18 f toward thesecond of the bedrails 18 f until an end 26 h of the first of thebedrails 18 f abuts an end 28 h of the second of the bedrails 18 f. Ifthe cross-sectional size of the void defined by the surface 56 of thebase layer 48 is smaller than the cross-sectional size of the splicemember 302, the splice member 302 may be disposed within the void in afriction-fit arrangement. The splice member 302 can increase thestrength and rigidity of the bedrails 18 f and the bedrail assembly 300.

With reference to FIG. 15, a drawer assembly 18 i is shown. Thestructure, function, and method of manufacturing the drawer assembly 18i may be substantially similar to that of the shelves 18, 18 a, 18 b, 18c, 18 d, 18 e or bedrails 18 f, 18 g, 18 h. Accordingly, the structureand/or function of similar features will not be described again indetail. In addition, like reference numerals are used hereinafter and inthe drawings to identify like features, while like reference numeralscontaining letter extensions (i.e., “i”) are used to identify thosefeatures that have been modified. While article 18 i is generally shownand described herein as being a “drawer assembly 18 i,” it will beappreciated that article 18 i may be utilized in various ways within thescope of the present disclosure. For example, the drawer assembly 18 imay be utilized as a “shelf” for use with the furniture unit 10.

As illustrated in FIG. 15, in some implementations, the drawer assembly18 i may include a front component 290, a box component 292, and drawertracks 282. The box component 292 may include a first side 280-1, asecond side 280-2, a third side 280-3, a fourth side 280-4, and a bottom280-5. The first side 280-1 may be spaced apart from and opposing thesecond side 280-2. The third side 280-3 may be spaced apart from andopposing the fourth side 280-4. The bottom 280-5 may extend from andbetween each of the first, second, third, and fourth sides 280-1, 280-2,280-3, 280-4. In some implementations, the third side 280-3 may include,or otherwise define, a first cavity 286-1. The fourth side 280-4 mayinclude, or otherwise define, a second cavity 286-2. While the first andsecond cavities 286-1, 286-2 are generally illustrated as definingrectangular (e.g., square) shapes, it will be appreciated that the firstand second cavities 286-1, 286-2 may each define another shape such as atriangle, a circle, or another polygon within the scope of the presentdisclosure. It will be appreciated that the drawer assembly 18 i mayinclude more or less than two cavities within the scope of the presentdisclosure.

With reference to FIGS. 16A-16C, the drawer assembly 18 i (e.g., the boxcomponent 292) may include, or otherwise be formed from, a substrate 46i having a layered construct. In this regard, the substrate 46 i mayinclude the base layer 48, the upper laminate layer 50, and the lowerlaminate layer 52. In some implementations, the substrate 46 i may beformed without the lower laminate layer 52.

As illustrated in FIG. 16A, the substrate 46 i may include a pluralityof portions 310-1, 310-2, . . . 310-n. In some implementations, thesubstrate 46 i may include thirteen portions 310-1 to 310-13. It will beappreciated that the substrate 46 i may include more or less thanthirteen portions 310-n within the scope of the present disclosure.

With further reference to FIG. 16A, in some examples, each of theplurality of portions 310-1 to 310-n may include a corresponding uppersurface 74-1, 74-2, . . . 74-n and a corresponding lower surface 90-1,90-2, . . . 90-n disposed on the opposite side of the substrate 46 ithan the upper surface 74-1, 74-2, . . . 74-n. In some implementations,each of the plurality of portions 310-1, 310-2, . . . 310-n may furtherinclude a corresponding first end 312-1, 312-2, . . . 312-n, acorresponding second end 314-1, 314-2, . . . 314-n spaced apart from thefirst end 312-1, 312-2, . . . 312-n, a corresponding first side 316-1,316-2, . . . 316-n, and a corresponding second side 318-1, 318-2, . . .318-n spaced apart from the first side 316-1, 316-2, . . . 316-n. Thesubstrate 46 i may define a thickness T extending between an uppersurface (e.g., upper surface 74-n) and a lower surface (e.g., lowersurface 90-n). The thickness T may be between two millimeters and tenmillimeters. In some implementations, the thickness may be substantiallyequal to five millimeters.

In some implementations, the substrate 46 i may include a plurality ofthe seams 104-1, 104-2, . . . 104-n. As illustrated in FIG. 16A, in someimplementations, the substrate 46 i may include twelve seams 104-1 to104-12. It will be appreciated that the drawer assembly 18 i may includemore or less than twelve seams 104-n within the scope of the presentdisclosure. The seams 104-1 to 104-12 may extend through the lowersurface 90-n of the substrate 46 i. In some configurations, the seams104-1 to 104-12 may extend through the lower surface 90-n, the lowerlaminate layer 52, and a portion of the base layer 48 of the substrate46 i.

In some implementations, a first seam 104-1 may be disposed between theeighth portion 310-8 and the sixth portion 310-6 of the substrate 46 i.The first seam 104-1 may extend from the first end 312-8, 312-6 to thesecond end 314-8, 314-6 of either the eighth portion 310-8 or the sixthportion 310-6 of the substrate 46 i. A second seam 104-2 may be disposedbetween the sixth portion 310-6 and the second portion 310-2 of thesubstrate 46 i. The second seam 104-2 may extend from the first end312-6, 312-2 to the second end 314-6, 314-2 of either the sixth portion310-6 or the second portion 310-2 of the substrate 46 i. A third seam104-3 may be disposed between the second portion 310-2 and the firstportion 310-1 of the substrate 46 i. The third seam 104-3 may extendfrom the first end 312-2, 312-1 to the second end 314-2, 314-1 of eitherthe second portion 310-2 or the first portion 310-1 of the substrate 46i.

In some configurations, a fourth seam 104-4 may be disposed between thefirst portion 310-1 and the fourth portion 310-4 of the substrate 46 i.The fourth seam 104-4 may extend from the first end 312-1, 312-4 to thesecond end 314-1, 314-4 of either the first portion 310-1 or the fourthportion 310-7 of the substrate 46 i. A fifth seam 104-5 may be disposedbetween the fourth portion 310-4 and the seventh portion 310-7 of thesubstrate 46 i. The fifth seam 104-5 may extend from the first end312-4, 312-7 to the second end 314-4, 314-7 of either the fourth portion310-4 or the seventh portion 310-7 of the substrate 46 i. A sixth seam104-6 may be disposed between the seventh portion 310-7 and the ninthportion 310-9 of the substrate 46 i. The sixth seam 104-6 may extendfrom the first end 312-7, 312-9 to the second end 314-7, 314-9 of eitherthe seventh portion 310-7 or the ninth portion 310-9 of the substrate 46i.

In some examples, a seventh seam 104-7 may be disposed between the tenthportion 310-10 and the third portion 310-3 of the substrate 46 i. Theseventh seam 104-7 may extend from the first end 312-10 to the secondend 314-10 of the tenth portion 310-10 of the substrate 46 i. An eighthseam 104-8 may be disposed between the third portion 310-3 and theeleventh portion 310-11 of the substrate 46 i. The eighth seam 104-8 mayextend from the first end 312-11 to the second end 314-11 of theeleventh portion 310-11 of the substrate 46 i. A ninth seam 104-9 may bedisposed between the twelfth portion 310-12 and the fifth portion 310-5of the substrate 46 i. The ninth seam 104-9 may extend from the firstend 312-12 to the second end 314-12 of the twelfth portion 310-12 of thesubstrate 46 i.

In some implementations, a tenth seam 104-10 may be disposed between thefifth portion 310-5 and the thirteenth portion 310-13 of the substrate46 i. The tenth seam 104-10 may extend from the first end 312-13 to thesecond end 314-13 of the thirteenth portion 310-13 of the substrate 46i. An eleventh seam 104-11 may be disposed between the first portion310-1 and the third portion 310-3 of the substrate 46 i. The eleventhseam 104-11 may extend from the first side 316-1, 316-3 to the secondside 318-1, 318-3 of either the first portion 310-1 or the third portion310-3 of the substrate 46 i. A twelfth seam 104-12 may be disposedbetween the first portion 310-1 and the fifth portion 310-5 of thesubstrate 46 i. The twelfth seam 104-12 may extend from the first side316-1, 316-5 to the second side 318-1, 318-5 of either the first portion310-1 or the fifth portion 310-5 of the substrate 46 i.

In some configurations, the seams 104-1 to 104-10 may extendsubstantially parallel (+/−5 degrees) to one another. The seams 104-1 to104-10 may extend substantially orthogonal to the eleventh seam 104-11and the twelfth seam 104-12. The eleventh seam 104-11 and the twelfthseam 104-12 may extend substantially parallel to one another.

With reference to FIGS. 16A-16C, a method a manufacturing the boxcomponent 292 may be substantially similar to the previously describedmethod of manufacturing the component of shelf section 12-1, 12-2, . . .12-n (i.e., shelf 18, lateral leg 20, medial leg 22, and backer 24). Inthis regard, the method of manufacturing the box component 292 mayinclude providing the tool 200 (e.g., a router, a blade, a bit, etc.)and using the tool to form the plurality of primary channels 202 in thesubstrate 46 i, e.g, by miter cutting the plurality of primary channels202 in the substrate 46 i. The number and location of the primarychannels 202 may correspond to the number and location of the seams104-1, 104-2, . . . 104-n, as previously described relative to method ofmanufacturing the component of shelf section 12-1, 12-2, . . . 12-n(i.e., shelf 18, lateral leg 20, medial leg 22, and backer 24).

With reference to FIG. 16B, the method may further include forming aplurality of apertures 284-1, 284-2, . . . 284-n in the substrate 46 i.The apertures 284-1, 284-2, . . . 284-n may extend through the lowerlaminate layer 52, the base layer 48, and the upper laminate layer 50.As illustrated in FIG. 16B, the apertures 284-n may be disposed atvarious locations in the substrate 46 i. While some of the apertures284-n (e.g., apertures 284-3) are generally illustrated as circularshapes, it will be appreciated that the apertures 284-n may each defineanother shape such as triangle, rectangle, oval, ellipse, or anotherpolygon within the scope of the present disclosure. It will beappreciated that the drawer assembly 18 i may include more or less thantwo apertures within the scope of the present disclosure.

As illustrated in FIGS. 16A and 16B, the method may include forming atleast one aperture 284-3 in each of the portions 310-2 through 310-5,and 310-8 through 310-13. As will be described in more detail below, inan assembled configuration, a first aperture 284-3 formed in the fourthportion 310-4 may be aligned with a first aperture 284-3 formed in theninth portion 310-9 and with an aperture 284-3 formed in the eleventhportion 310-11.

In some implementations, in an assembled configuration, a component(e.g., screw, nail, pin, etc.) may be disposed within the foregoingapertures 284-3 formed in the fourth portion 310-4, the ninth portion310-9 and the eleventh portion 310-11. In some examples, a pin may bedisposed within the foregoing apertures 284-3 to aid in securing thefourth portion 310-4, the ninth portion 310-9 and the eleventh portion310-11 together.

In some implementations, in an assembled configuration, a secondaperture 284-3 formed in the fourth portion 310-4 may be aligned with asecond aperture 284-3 formed in the ninth portion 310-9 and with anaperture 284-3 formed in the thirteenth portion 310-13. A component(e.g., screw, nail, pin, etc.) may be disposed within the foregoingapertures 284-3 formed in the fourth portion 310-4, the ninth portion310-9 and the thirteenth portion 310-13. In some examples, a pin may bedisposed within the foregoing apertures 284-3 to aid in securing thefourth portion 310-4, the ninth portion 310-9 and the thirteenth portion310-13 together.

In some configurations, in an assembled configuration, a first aperture284-3 formed in the second portion 310-2 may be aligned with a firstaperture 284-3 formed in the eighth portion 310-8 and with an aperture284-3 formed in the tenth portion 310-10. A component (e.g., screw,nail, pin, etc.) may be disposed within the foregoing apertures 284-3formed in the second portion 310-2, the eighth portion 310-8 and thetenth portion 310-10. In some examples, a pin may be disposed within theforegoing apertures 284-3 to aid in securing the second portion 310-2,the eighth portion 310-8 and the tenth portion 310-10 together.

In some implementations, in an assembled configuration, a secondaperture 284-3 formed in the second portion 310-2 may be aligned with asecond aperture 284-3 formed in the eighth portion 310-8 and with anaperture 284-3 formed in the twelfth portion 310-12. A component (e.g.,screw, nail, pin, etc.) may be disposed within the foregoing apertures284-3 formed in the second portion 310-2, the eighth portion 310-8 andthe twelfth portion 310-12. In some examples, a pin may be disposedwithin the foregoing apertures 284-3 to aid in securing the secondportion 310-2, the eighth portion 310-8 and the twelfth portion 310-12together.

The method may also include forming a pair of apertures 284-1, 284-2 ineach of the portions 310-4, 310-2, such that in the assembledconfiguration, the third side 280-3 and the fourth side 280-4 eachinclude first and second apertures 284-1, 284-2. The apertures 284-1,284-2 of the third side 208-3 may be accessible on an outer surface 328of the third side 280-3 and may be in communication with the firstcavity 286-1. The apertures 284-1, 284-2 of the fourth side 208-4 may beaccessible on an outer surface 328 of the fourth side 280-4 and may bein communication with the second cavity 286-2. The apertures 284-1,284-2 of the third and the fourth sides 280-3, 280-4 may include anelongate shape. In this regard, as illustrated in FIG. 16B, the firstaperture 284-1 may have a major axis A1 extending in a first directionand the second aperture 284-2 may have a major axis A2 extending in asecond direction. The second direction may be transverse (e.g.,perpendicular) to the first direction. In some implementations, thefirst and the second apertures 284-1, 284-2 may include a first portionand a second portion. The first portion may be larger than the secondportion. In particular, the first portion of the apertures 284-1, 284-2may cover a larger area than that of the second portion of the apertures284-1, 284-2. In some examples, the first portion of the apertures284-1, 284-2 may include a substantially circular shape and the secondportion of the apertures 284-1, 284-2 may include a substantiallyelongate shape.

With continued reference to FIG. 16B, the method may also includefolding the substrate 46 i such that each first channel wall 204 of theprimary channel 202 engages the second channel wall 206 of the sameprimary channel 202 to define a corresponding seam 104-n and fold 106-n.For example, the method may include performing a plurality of foldingoperations to define the plurality of seams 104-1, 104-2, . . . 104-nand the plurality of folds 106 i-1, 106 i-2, . . . 106 i-n may define,or otherwise as, a hinge for folding the substrate 46 i. Accordingly,each fold 106 i-1, 106 i-2, . . . 106 i-n may be referred to herein as ahinge 106 i-1, 106 i-2, . . . 106 i-n.

In some implementations, prior to conducting the folding operations, anadhesive 322 (e.g., a glue) may be applied in at least one of theprimary channels 202. In some implementations, the adhesive 322 may beapplied in all of the primary channels 202.

As illustrated in FIG. 16C, in some implementations, the foldingoperations, and the plurality of seams 104-1, 104-2, . . . 104-n and theplurality of folds 106 i-1, 106 i-2, . . . 106 i-n defined thereby, formthe first side 280-1, the second side 280-2, the third side 280-3, thefourth side 280-4, the first cavity 286-1 and the second cavity 286-2 ofthe box component 292 of the drawer assembly 18 i.

With reference to FIGS. 16A and 16C, in some implementations, the firstside 280-1 of the box component 292 may be formed when the third portion310-3 of the substrate 46 i is folded along the eleventh fold 106 i-11to engage the first portion 310-1 of the substrate 46 i. The second side280-2 of the box component 292 may be formed when the fifth portion310-5 of the substrate 46 i is folded along the twelfth fold 106 i-12 toengage the first portion 310-1 of the substrate 46 i.

In some examples, the tenth portion 310-10 of the substrate 46 i may befolded along the seventh fold 106 i-7 to engage the third portion 310-3of the substrate 46 i, the eleventh portion 310-11 of the substrate 46 imay be folded along the eighth fold 106 i-8 to engage the third portion310-3 of the substrate 46 i, the twelfth portion 310-12 of the substrate46 i may be folded along the ninth fold 106 i-9 to engage the fifthportion 310-5 of the substrate 46 i, and the thirteenth portion 310-13of the substrate 46 i may be folded along the tenth fold 106 i-10 toengage the fifth portion 310-5 of the substrate 46 i.

In some implementations, at least one of upper surface 74-10 or thelower surface 90-10 of the tenth portion 310-10 of the substrate 46 imay include an adhesive (e.g., glue, two-sided tape, etc.), and at leastone of upper surface 74-11 or the lower surface 90-11 of the eleventhportion 310-11 of the substrate 46 i may include an adhesive. In someexamples, at least one of upper surface 74-12 or the lower surface 90-12of the twelfth portion 310-12 of the substrate 46 i may include anadhesive, and at least one of upper surface 74-13 or the lower surface90-13 of the thirteenth portion 310-13 of the substrate 46 i may includean adhesive.

In some implementations, the third side 280-3 of the box component 292may be formed when (i) the fourth portion 310-4 of the substrate 46 i isfolded along the fourth fold 106 i-4 to engage the first portion 310-1of the substrate 46 i, (ii) the seventh portion 310-7 of the substrate46 i is folded along the fifth fold 106 i-5 to engage the fourth portion310-4 of the substrate 46 i, and (iii) the ninth portion 310-9 of thesubstrate is folded along the sixth fold 106 i-6 to engage the seventhportion 310-7 of the substrate 46 i and the first portion 310-1 of thesubstrate 46 i. In particular, (i) the lower surface 90-4 of the fourthportion 310-4 may engage the upper surfaces 74-11, 74-13 of the eleventhand thirteen portions 310-11, 310-13, (ii) the lower surface 90-9 of theninth portion 310-9 may engage the lower surfaces 90-11, 90-13 of theeleventh and thirteen portions 310-11, 310-13, and (iii) the first side316-9 of the ninth portion 310-9 of the substrate 46 i may engage thelower surface 90-1 of the first portion 310-1. In some examples, uponcompletion of the foregoing folding operations, the fourth portion 310-4of substrate 46 i is spaced apart from the ninth portion 310-9 of thesubstrate 46 i thereby forming a first cavity 286-1 between the fourthand the ninth portions 310-4, 310-9.

In an assembled configuration, the eleventh portion 310-11 of thesubstrate 46 i may be disposed within the first cavity 286-1, therebyaligning the first apertures 284-3 formed in the fourth and the ninthportions 310-4, 310-9 with the aperture 284-3 formed in the eleventhportion 310-11. The thirteenth portion 310-13 of the substrate 46 i maybe disposed within the first cavity 286-1, thereby aligning the secondapertures 284-3 formed in the fourth and the ninth portions 310-4, 310-9with the aperture 284-3 formed in the thirteenth portion 310-13.

As illustrated in FIGS. 16A and 16B, in some implementations, the ninthportion 310-9 of the substrate 46 i may include at least one tab portion324 extending from the first side 316-9 of the ninth portion 310-9. Uponthe completion of the foregoing folding operations, each tab portion 324of the ninth portion 310-9 may be disposed within a corresponding recess326 formed in the lower surface 90-1 of the first portion 310-1 tosecure the box component 292 in the folded configuration. In someexamples, the recess 326 may have a substantially similar shape as thetab portion 324.

With reference to FIGS. 16A and 16C, in some implementations, the fourthside 280-4 of the box component 292 may be formed when (i) the secondportion 310-2 of the substrate 46 i is folded along the third fold 106i-3 to engage the first portion 310-1 of the substrate 46 i, (ii) thesixth portion 310-6 of the substrate 46 i is folded along the secondfold 106 i-2 to engage the second portion 310-2 of the substrate 46 i,and (iii) the eighth portion 310-8 of the substrate is folded along thefirst fold 106 i-1 to engage the sixth portion 310-6 of the substrate 46i and the first portion 310-1 of the substrate 46 i. In particular, (i)the lower surface 90-2 of the second portion 310-2 may engage the uppersurfaces 74-10, 74-12 of the tenth and twelfth portions 310-10, 310-12,(ii) the lower surface 90-8 of the eighth portion 310-8 may engage thelower surfaces 90-10, 90-12 of the tenth and twelfth portions 310-10,310-12, and (iii) the second side 318-8 of the eighth portion 310-8 ofsubstrate 46 i may engage the lower surface 90-1 of the first portion310-1. In some examples, upon completion of the foregoing foldingoperations, the second portion 310-2 of substrate 46 i is spaced apartfrom the eighth portion 310-8 of the substrate 46 i thereby forming asecond cavity 286-2 between the second and eighth portions 310-2, 310-8.

In an assembled configuration, the tenth portion 310-10 of the substrate46 i may be disposed within the second cavity 286-2, thereby aligningthe first apertures 284-3 formed in the second and the eighth portions310-2, 310-8 with the aperture 284-3 formed in the tenth portion 310-10.The twelfth portion 310-12 of the substrate 46 i may be disposed withinthe second cavity 286-2, thereby aligning the second apertures 284-3formed in the second and the eighth portions 310-2, 310-8 with theaperture 284-3 formed in the twelfth portion 310-12.

As illustrated in FIGS. 16A and 16B, in some implementations, the eighthportion 310-8 of the substrate 46 i may include at least one tab portion324 extending from the second side 318-8 of the eighth portion 310-8.Upon the completion of the foregoing folding operations, each tabportion 324 of the eighth portion 310-8 may be disposed within acorresponding recess 326 formed in the lower surface 90-1 of the firstportion 310-1 to secure the box component 292 in the foldedconfiguration. In some examples, the recess 326 may have a substantiallysimilar shape as the tab portion 324.

With reference to FIGS. 18A, 18B and 19, in some implementations, acomponent (e.g., a drawer track, bracket, etc.) may be detachablycoupled to the third side 280-3 of the box component 292. In someimplementations, a first drawer track 282-1 may include at least one peg283. In some examples, a first peg 283-1 of the first drawer track 282-1may be disposed within the first aperture 284-1 of the third side 280-3and at least partially within the first cavity 286-1, while a second peg283-2 of the first drawer track 282-1 may be disposed within the secondaperture 284-2 of the third side 280-3 and at least partially within thefirst cavity 286-1, thereby securing the first drawer track 282-2 to thebox component 292.

In some implementations, a method of securing the first drawer track282-1 to the box component 292 may include positioning the second peg283-2 of the first drawer track 282-1 within the first portion of thesecond aperture 284-2. The method may subsequently include moving thesecond peg 283-2 along the axis A2 from the first portion of the secondaperture 284-2 to the second portion of the second aperture 284-2,thereby securing the second peg 283-2 within the first cavity 286-1. Insome implementations, the method of securing the first drawer track282-1 to the box component 292 may also include positioning the firstpeg 283-1 of the first drawer track 282-1 within the first portion ofthe first aperture 284-1, and moving the first peg 283-1 along the axisA1 to the second portion of the first aperture 284-1, thereby securingthe first peg 283-1 within the first cavity 286-1.

With continued reference to FIGS. 18A, 18B and 19, in someimplementations, a component (e.g., a drawer track, bracket, etc.) maybe detachably coupled to the fourth side 280-4 of the box component 292.In some implementations, a second drawer track 282-2 may include atleast one peg 283. In some examples, a first peg 283-1 of the seconddrawer track 282-2 may be disposed within the first aperture 284-1 ofthe fourth side 280-4 and at least partially within the second cavity286-2, while a second peg 283-2 of the second drawer track 282-2 may bedisposed within the second aperture 284-2 of the fourth side 280-4 andat least partially within the second cavity 286-2, thereby securing thesecond drawer track 282-2 to the box component 292.

In some implementations, a method of securing the second drawer track282-2 to the box component 292 may include positioning the second peg283-2 of the second drawer track 282-2 within the first portion of thesecond aperture 284-2. The method may subsequently include moving thesecond peg 283-2 along the axis A1 from the first portion of the secondaperture 284-2 to the second portion of the second aperture 284-2,thereby securing the second peg 283-2 within the second cavity 286-2. Insome implementations, the method of securing the second drawer track282-2 to the box component 292 may also include positioning the firstpeg 283-1 of the second drawer track 282-2 within the first portion ofthe first aperture 284-1, and moving the first peg 283-1 along the axisA1 to the second portion of the first aperture 284-1, thereby securingthe first peg 283-1 within the second cavity 286-2.

With reference to FIG. 15, in some implementations, the drawer assembly18 i may include a front component 290 detachably connected to andconfigured to cover at least a portion of the first side 280-1 of thebox component 292. The method of manufacturing the front component 290may be substantially similar to that of the drawer assembly 18 i.Accordingly, the structure and or function of similar features will notbe described again detail. In addition, like reference numerals are usedhereinafter and in the drawings to identify like features, while likereference numerals containing letter extension (i.e., “j”) are used toidentify those features that have been modified.

As illustrated in FIG. 17A, the front component 290 may include a cavity286, a first cutout 296-1, a second cutout 296-2, and at least oneaperture 294. With reference to FIG. 15, a portion of the first side280-1 of the box component 292 may be disposed within the cavity 286 ofthe front component 290, a portion of the fourth side 280-4 of the boxcomponent 292 may be disposed within the first cutout 296-1, and aportion of the third side 280-3 of the box component 292 may be disposedwithin the second cutout 296-2. In some examples, the front component290 may include first and second apertures 294-1, 294-2 which may bealigned with apertures 284 within the first side 280-1 of the boxcomponent 292. In some implementations, a component (e.g., a handle,knob, etc.) may be detachably coupled to the front component 290. Inparticular, a portion of a handle 288 may be disposed within the firstand second apertures 291-1, 291-2 of the front component 290, and theapertures 284 of the first side 280-1 of the box component 292.

With reference to FIGS. 17A and 17B, the front component 290 mayinclude, or otherwise be formed from, a substrate 46 j having a layeredconstruct. In this regard, the substrate 46 j may include a base layer48, an upper laminate layer 50, and a lower laminate layer 52. Asillustrated in FIG. 17B, the substrate 46 j may include a plurality ofportions 310 j-1, 310 j-2, . . . 310 j-n. In some implementations, thesubstrate 46 j may include six portions 310 j-1 to 310 j-6. It will beappreciated that the substrate 46 j may include more or less than sixportions 310 j-n within the scope of the present disclosure.

In some implementations, the front component 290 may include a pluralityof seams 104-1, 104-2, . . . 104-n. As illustrated in FIG. 17B, in someimplementations, the front component 290 may include five seams 104-1 to104-5. It will be appreciated that the front component 290 may includemore or less than five seams 104-n within the scope of the presentdisclosure. The seams 104-1 to 104-5 may extend through the uppersurface 50 of the substrate 46 i. In some configurations, the seams104-1 to 104-5 may extend through the upper surface 50 and the baselayer 48 of the substrate 46 i.

With reference to FIGS. 17A and 17B, the front component 290 may beformed by performing a plurality of folding operations to define theplurality of seams 104-1, 104-2, . . . 104-n and the plurality of folds106 j-1, 106 j-2, . . . 106 j-n may define, or otherwise as, a hinge forfolding the substrate 46 j. Accordingly, each fold 106 j-1, 106 j-2, . .. 106 j-n may be referred to herein as a hinge 106 j-1, 106 j-2, . . .106 j-n. In some implementations, the front component 290 may be formedby folding the second portion 310 j-2 of the substrate 46 j along thefourth fold 106 j-4 to engage the first portion 310 j-1, folding thethird portion 310 j-3 along the first fold 106 j-1 to engage the firstportion 310 j-1, folding the fourth portion 310 j-4 along the secondfold 106 j-2 to engage the first portion 310 j-1, folding the fifthportion 310 j-5 along the third fold 106 j-3 to engage the first portion310 j-1, and folding the sixth portion 310 j-6 along the fifth fold 106j-5 to engage the third portion 310 j-3.

The configuration of, and related methods of manufacturing, thefurniture unit 10 described herein, including, for example, the variouschannels 202, and the seams 104-n and folds 106-n formed thereby, canallow a user to easily and efficiently manufacture the shelves 18, 18 a,18 b, 18 c, 18 d, 18 e, the bedrails 18 f, 18 g, 18 h, the drawerassembly 18 i, the furniture unit 10, and the bedrail assembly 300 tohave superior strength and durability.

The foregoing description has been provided for purposes of illustrationand description. It is not intended to be exhaustive or to limit thedisclosure. Individual elements or features of a particularconfiguration are generally not limited to that particularconfiguration, but, where applicable, are interchangeable and can beused in a selected configuration, even if not specifically shown ordescribed. The same may also be varied in many ways. Such variations arenot to be regarded as a departure from the disclosure, and all suchmodifications are intended to be included within the scope of thedisclosure.

What is claimed is:
 1. A drawer assembly comprising: a bottom; a firstside extending from the bottom; a second side extending from the bottomopposite the first side, the second side including a first wall portionand a second wall portion opposite the first wall portion, the firstwall portion spaced apart from the second wall portion to define a firstcavity therebetween, the first wall portion including a first aperturein fluid communication with the first cavity;
 2. The drawer assembly ofclaim 1, further comprising a third side extending between the firstside and the second side.
 3. The drawer assembly of claim 2, furthercomprising a front component detachably connected to the third side. 4.The drawer assembly of claim 1, wherein the first wall portion includesa second aperture spaced apart and linearly aligned with the firstaperture, the second aperture in communication with the first cavity. 5.The drawer assembly of claim 4, wherein a first component is detachablyconnected to the second side.
 6. The drawer assembly of claim 5, whereinportions of the first component are disposed through the first and thesecond apertures.
 7. The drawer assembly of claim 6, wherein the firstcomponent is a drawer track.
 8. The drawer assembly of claim 3, whereinthe front component includes a first portion having a first and a secondend and a second portion spaced apart and opposing the first portion. 9.The drawer assembly of claim 8, wherein the second portion of the frontcomponent extends from the first end of the first portion in a directiontowards the second end of the first portion, the second portionterminating before the second end of the first portion.
 10. The drawerassembly of claim 9, wherein the front component includes a secondcavity disposed between the first portion and the second portion, andwherein a portion of the third side of the drawer assembly is disposedwithin the second cavity.
 11. The drawer assembly of claim 10, whereinthe second portion of the front component includes a first and a secondcutout, wherein a portion of the first side of the drawer assembly isdisposed within the first cutout, and wherein a portion of the secondside of the drawer assembly is disposed within the second cutout. 12.The drawer assembly of claim 11, wherein the front component includes athird and a fourth aperture, wherein the third side of the drawerassembly includes a fifth and a sixth aperture, and wherein the thirdaperture is aligned with the fifth aperture and the fourth aperture isaligned with the sixth aperture.
 13. The drawer assembly of claim 12,wherein a handle in detachably coupled to the front component, andwherein a portion of the handle is disposed within the third, fourth,fifth and sixth apertures.
 14. A method of assembling a drawer assembly,the method comprising: folding a substrate at a first channel to form afirst side; folding the substrate at a second channel to form a secondside; folding the substrate at a third channel, a fourth channel, and afifth channel to form a third side having a first cavity; and foldingthe substrate at a sixth channel, a seventh channel, and an eighthchannel to form a fourth side having a second cavity.
 15. The method ofclaim 14, further comprising applying an adhesive to at least one of thefirst channel, the second channel, the third channel, the fourthchannel, the fifth channel, the sixth channel, the seven channel and theeighth channel prior to folding.
 16. The method of claim 14, wherein thethird side of the substrate includes a first aperture in communicationwith the first cavity and the fourth side of the substrate includes asecond aperture in communication with the second cavity.
 17. The methodof claim 16, further comprising detachably connecting a first componentto an outer surface of the third side of the substrate, and detachablyconnecting a second component to an outer surface of the fourth side ofthe substrate.
 18. The method of claim 17, wherein a portion of thefirst component is disposed through the first aperture of the third sideof the substrate, and a portion of the second component is disposedthrough the second aperture of the fourth side of the substrate.
 19. Themethod of claim 18, wherein the first and the second components aredrawer tracks.
 20. The method of claim 14, further comprising detachablyconnecting a front component to the first side of the substrate, whereinthe front component is configured to cover the first side of thesubstrate.
 21. The method of claim 20, wherein the front componentincludes a third cavity, and wherein the first side of the substrate isdisposed within the third cavity.
 22. The method of claim 21, whereinthe front component includes a first and a second cutout, wherein thethird side of the substrate is disposed within the first cutout, andwherein the fourth side of the substrate is disposed within the secondcutout.
 23. The method of claim 22, wherein the front component includesa first aperture, wherein the first side of the substrate includes asecond aperture, and wherein the first aperture is aligned with thesecond aperture.
 24. The method of claim 23, further comprisingdetachably connecting a handle to the front component of the drawerassembly, wherein a portion of the handle is disposed within the firstaperture of the front component and the second aperture of the firstside of the substrate.